Expanded foraminous plastic article



Jan. 26, 1965 s. P. CRANE EXPANDED FORAMINOUS PLASTIC ARTICLES FiledAug. 16, 1962 E INVENTOR.

Samuel P Crane United States Patent 3,167,353 EXPANDED FORAMINOUSPLASTIC ARTICLE Samuel P. Crane, 23 Pine Drive, Great Neck, N.Y. FiledAug. 16, 1962, Ser. No. 217,344 19 Claims. (Cl. 297453) This inventionrelates to fabricated foraminous and expanded articles of plasticmaterial and particularly to ventilated seat spacers or cushions or thelike made of such material.

One of the objects of the invention is the provision of a one pieceforaminous expanded plastic sheet or molded member having net-likeimperforate linear and coplanar bracing portions of substantial area andhaving closely spaced arch shaped laterally outstanding elements adaptedto serve as a support when relatively rigid or as a cushion when more orless resilient, the elements when formed from a sheet being pressed fromthe sheet material between a suitable series of discontinuous slits, thesheet or molded member being so fabricated as to leave ventilatingopenings bridged by the elements and communicating with the spaces inthe elements.

A further object of the invention is the provision of a foraminousmember of relatively thin material but of relatively great overallthickness, having spaced apart raised elements separated by continuousimperforate planar bracing strips integral with the member and capableof supporting considerable stress while dimensionally stable andgenerally self-adjusting to the contour of the surface against which itis pressed.

A further object of the invention is the provision of an inexpensivedurable foraminous seat-ventilating cushion or spacer primarily of asingle piece of laterally expanded plastic braced in two substantiallyperpendicular directions against objectional distortion when in use, butsufliciently flexible to adjust itself, under load, to the shape of itssupporting surface, such as an automobile cushion.

A further object of the invention is the provision of a shapedventilating cushion or spacer made of the foraminous member abovementioned and having an integral substantially imperforate marginalportion provided with reinforcement against undue distortion, thecushion being adapted for manufacture with integral or with separateseat and back portions which are relatively adjustable.

A still further object of the invention is the provision of a one pieceplastic ventilating cushion or spacer which is rigid enough and includesenough seating or bearing areas for comfortable support of the user,while flexible enough to conform to the shape of its supporting seatcushion and which requires no covering material on either face thereofand which is adapted to have friction or antislip strips and flat edgesprings woven thereinto.

The various objects of the invention will further become clear from thefollowing description and from the accompanying drawings, in which FIG.1 is a fragmentary perspective view of an expanded fabricated sheet ormolded member, some of the outstanding arched elements being omitted toshow more clearly the ventilating openings and the integral imperforaterows of net-like cross bracing strips, which create a foraminous member.

FIG. 2 is a fragmentary top plan view of a ventilating spacer utilizingthe member of FIG. 1 and showing the marginal reinforcement as well asthe under friction or anti-slip strips woven into the elements.

FIG. 3 is a vertical sectional view taken on the line 33 of FIG. 2.

FIG. 4 is a fragmentary top plan view of a modified form of the expandedmember.

FIG. 5 is a vertical sectional view taken on the line 5-5 of FIG. 4.

FIG. 6 is a fragmentary top plan view of another form of the arch-likeelements of the member, showing an integral strengthening rib therein.

FIG. 7 is a plan view of half of a modified form of the cushion orspacer, in which the arch-like elements are arranged in a series ofconcentric circles instead of parallel rows, the other half being thesame as that shown.

FIG. 8 is a plan view of a cushion or spacer in which the arch-likeelements alternate and in which the seat part and back part are madefrom a single sheet and are normally held in a coplanar position bystrip springs loosely woven into the sides of the cushion.

FIG. 9 is a fragmentary vertical sectional view taken on the line 9-9 ofFIG. 8.

FIG. 10 is a similar view of the same showing a modified form of themarginal reinforcement.

FIG. 11 is a similar view of the same showing another form of themarginal reinforcement.

FIG. 12 is a fragmentary plan view of a cushion or spacer similar tothat of FIG. 8, but showing the back and seat parts as separate piecesheld together adjustably by the side springs which are wedged intoadjusted positions.

FIG. 13 is a fragmentary vertical sectional view taken on the line 1313of FIG. 12.

As has been indicated, the fabricated member shown in FIG. 1 has varioususes and may be made of various plastics having the characteristicsrequired for special uses. It may also be made by various processes suchas shaping a relatively thin sheet of uniform thickness by heat andpressure between suitable dies or by molding or the like. Whenfabricated from a sheet, selected areas between discontinuous slits arepressed laterally out of the initial plane of the sheet into theoutstanding generally arch-shaped elements desired, while permittinglinear bracing portions to remain unchanged and thereby to produce aforaminous or net-like member having openings therein bridged by theelements. When expanded to a considerable extent, parts of the elementsmay decrease in thickness by the excessive lengthening thereof, but suchdecrease is compensated for by curving the element material, impressinga rib thereinto or otherwise shaping the parts of the element toincrease its strength. When made by molding processes, the parts whichtake the greatest stresses are obviously made thickest. In what follows,the expanded member as well as the articles made therefrom, will bedescribed as though the outstanding elements thereof were made from asheet, though it will be understood that other appropriate processes maybe utilized to attain substantially the same form of the expandedmember.

In the form shown in FIG. 1, a series of longitudinally alignedseparated slits as 16 are arranged in a row along a straight line. Asimilar but opposed series of companion slits 26:: parallel to andspaced transversely away from the slits 16 are made in the sheet. Thematerial forced laterally or outwardly from between the companion slitsand out of the initial plane of the sheet is shaped as desired, which ispreferably in the general form of a trapezoidal arch to form asupporting element bridging the resulting opening in the sheet. Asshown, the element has a flat top 17 parallel to the plane of the sheet,and outwardly converging sides 18 and 19 of substantial height. The flattops provide discontinuous bearing areas for the support of the load,and are close enough for a user to sit on or lean against withoutdiscomfort when the member 15 is incorporated into a ventilating cushionor spacer.

The openings, formed between companion pairs of slits 16 and 16a by theremoval or displacement of material to form the elements, are in spacedrelation to each other, being separated by the preferably imperfor-atebracing strips 22 extending lengthwise of the openings 20 completelyacross the member. Said openings 20 communicate with the spaces in theelements to permit the circulation through the member of enough air toadequately ventilate the member, while the bracing strips resist bendingon lines extending between the ends of adjacent openings therebyavoiding objectionable limpness or distortion of the member in onedirection. To stiffen the member as well against bending in aperpendicular direction and thereby to form a net-like area ofsubstantial extent, the slits 16 of each row of such slits, as well asthe slits 16a of the companion row, are spaced apart longitudinally sothat a substantial area of imperforate material separates the ends ofthe slits in each row of the entire set of such rows. Such imperforateareas merge into bracing strips 23 extending completely along the memberand form a set intersecting the set of strips 22.

It will be understood that the shapes and sizes of the slits, openingsand outstanding elements may be varied to a considerable extent. InFIGS. 1-3, the elements alternate in arrangement in a single row to forma set extending upwardly from the general plane of the connectingbracing strips 22 and 23 and a second set in the same rows extendingdownwardly. The first set constitutes the crests 24 and the alternateset constitutes the troughs 25. Such crests and troughs also alternatein the transverse set of rows parallel to the bracing strips 23. As aresult, the overall thickness of the member 15 is considerable. It isdue to the foraminous structure of the member that it is adequatelyventilated without sacrifice of its supporting properties and whilepermitting some flexibility in the member even though it may be made ofrelatively rigid plastic.

When the plastic used is of greater resiliency than that required forseat ventilators, the member may be employed in shipping packages as aprotecting packing cushion, or for other cushioning purposes where aresilient supporting pad is desirable.

In FIGS. and 6 is shown a member 26 in which only outstanding crests areprovided as elements, the troughs having been omitted in order to attaindenser or more closely spaced bearing areas than would be possible ifthe troughs were present. The arch-shaped crests are aligned in rowslengthwise of the openings 20 similarly to those shown in FIGS. 1-3, butthe crests differ in arrangement, those of FIGS. 5-6 having adjacentrows which are relatively staggered. The transverse bracing strips 28between the ends of adjacent elements in each row consequently are notcontinuous or straight, but are undulating. The flat tops 17 of elementsin adjacent rows overlap somewhat and decrease the spacing of thebearing areas as compared to the form of FIGS. 1-3. In addition, oroptionally, the converging outstanding sides 29, 30 of the elements arecurved in cross section better to resist bending or collapse under loadthan when flat.

In the form of the element shown in FIG. 6, all three sides are providedwith suitable outstanding ribs as 31 to strengthen said sides, it beingunderstood that such ribs may be provided, if desired, in any of theelements hereinbefore described.

The expanded plastic member, no matter how it is fabricated, isparticularly useful in a ventilating cushion or spacer for an automobileseat. For such use, the marginal portion 33 of the sheet (FIGS. 2 and 3)preferably remains imperforate for stiffening purposes and may beadditionally reinforced or stiffened in a number of ways. In FIGS. 2 and3, the peripheral portion 34 is curved underneath and around thepreferably plastic welt or core 35 and heat sealed to the marginalportion 33.

In FIG. 7, the outstanding elements are arranged in concentric rows as36, 37 to form a disc shaped cushion or spacer, leaving concentricbracing strips 39 between the radial rows of elements. It will beunderstood that the arrangement of the rows of elements does not necessarily depend on the outline of the shape selected for the cushion,provided that at least two sets of intersecting bracing strips separateand stiffen the elements and the member. As shown in FIG. 7, radialbracing strips 38 remain between adjacent radial rows of the elements.The curved marginal flange 40 serves to retain the border stiffeningmember 41 in place.

In FIG. 8 is illustrated the application of the member as 15 or the liketo a generally rectangular one piece seat cushion or spacer having aseat part 42 and a back part 43 integral therewith. The area 44 betweensaid parts remains imperforate. Through the side marginal portions 45,46 short transverse spaced apart slits are made as 47, through whichsuitable fiat springs as 49 (FIG. 9) are woven. The springs are normallyflat spring strips shaped to maintain the parts in coplanar positionswhen unloaded and unstressed, but are soft enough to yield readily andto permit the parts to assume mutually perpendicular positions wherebythe seat part may be arranged to rest on the seat cushion of anautomobile and the back part against the back cushion. The edges of thecushion or spacer, regardless of the shape of its outline or of theshape or arrangement of the rows of outstanding elements thereof,terminate in outstanding flanges as 50 substantially perpendicular tothe general plane of the expanded member and serves as a means forstiffening the cushion against undue bending and aiding the longitudinaland transverse bracing strips between the elements to attain therequired resistance to bending.

In FIG. 10, the edge stiffening means takes the form of an inturnedspringy cylindrical edge portion 51 enclosing a socket-like space 52having a flared lip 53 constricting the entrance opening to said spaceand adapted to receive the border frame 54 of suitable stiffeningmaterial. The frame is forced past the lip, which yields to enlarge theentrance opening and to permit the frame to move therepast and into thefurthermost part of the socket 52, the lip being released and againrestricting the opening after the passage of the frame therepast.

As shown in FIG. 11, the edge reinforcing or stiffening means comprisescorrugations or ribs as 55 in the marginal portion of the cushion,optionally combined with the outstanding flange 56.

Should it be desired to have separate seat and back parts for thecushion, as shown in FIGS. 12 and 13, such parts are adjustablyconnected by the flat springs 49 woven through the slits 47 of saidparts as in FIGS. 8 and 9. The seat and back parts are slid along thesprings until the space 57 therebetween is adjusted to the requiredwidth, whereafter the springs are secured to the parts in any suitablemanner as by Wedging them into the slits, or by snap fasteners or thelike. Wedges as 58 are shown diagrammatically in FIG. 13 to preventundesired movement of the seat and back parts relatively to each otherand to the springs.

To resist slippage of the cushion on its seat, suitable anti-friction(such as rubber) strips as 60 (FIGS. 2 and 3) are woven through thespaces in the elements in position to contact the seat on which thecushion rests. In the form of FIGS. 5 and 6, the strips may be woventhrough the openings 20 in a similar manner.

It will now be seen that the expanded member herein described may assumea variety of forms by the proper spacing sizes and arrangements of theelements, openings and bracing strips thereof; that such member hasvarious uses and may be made of various plastics by various processesdepending on the type of load thereon and the desired rigidity strengthflexibility and resilience thereof, that when used in cushions, suchcushions are made in any desired shape of a single piece of plasticother than the edge reinforcing means added thereto, that adequateprovision is made for ventilation through the openings and communicatingspaces in the member and that the various objects of the invention havebeen adequately attained.

While certain specific forms of the invention have herein been shown anddescribed, various obvious changes may be made therein without departingfrom the spirit of the invention defined by the appended claims.

I claim:

1. In a fabricated expanded plastic member of greater overall heightthan the thickness of the material thereof, a foraminous generallyplanar one piece portion having integral sets of intersecting stiffeningstrips surrounding and defining rows of longitudinally and transverselyspaced apart openings in said portion, and outstanding generallyarch-shaped elements integral with said portion and each bridging one ofthe openings and having a top of substantial area, the elements beingsufiiciently rigid and closely spaced enough to support a load, therebeing spaces in the elements communicating with the openings and ofsuflicient volume for the circulation of air through the member.

2. The plastic member of claim 1, the member being sufiiciently flexibleto conform, when loaded, to the contour of the surface on which themember rests, one set of strips comprising parallel rows in transversespaced relation to each other, and the intersecting set of stripscomprising rows in longitudinal spaced relation to each other.

3. The plastic member of claim 1, alternate elements outstandinglaterally at the openings in opposite directions.

4. The plastic member of claim 1, the tops of the elements being flat,the elements being arranged in transversely and longitudinally extendingsets of rows, each of the stiffening strips of one set being parallel toand between a pair of adjacent elements of adjacent transverselyextending rows, each of the strips of the other set of stiffening stripsbeing interposed between a pair of adjacent rows of the longitudinallyextending set of rows.

5. The plastic member of claim 4, each strip of one set of stilfeningstrips being straight and continuous and each strip of the other setbeing discontinuous, adjacent rows of elements of one of the sets ofsaid rows being staggered relatively to each other.

6. A ventilating cushion comprising the member of claim 1, an integralcoplanar extension of the foraminous portion constituting asubstantially imperforate marginal part around the periphery of thecushion, said extension being curved to extend laterally and thereby tostitfen said marginal part.

7. The cushion of claim 6, and a reinforcing border member held by andWithin the marginal part.

8. A one piece plastic ventilating cushion sufiiciently flexible toconform, when loaded, to the contour of a seat on which the cushionrests or leans, comprising a marginal portion, reinforcing means at theperiphery of said portion, and a laterally expanded portion integralwith the marginal portion and comprising a net-like part havinglongitudinally and transversely extending and spaced apart rows ofopenings therein and laterally outstanding elements of arch-like shapeeach bridging one of the openings and thereby being spacedlongitudinally away from adjacent elements in the same row andtransversely away from adjacent elements in adjacent rows.

9. The cushion of claim 8, the cushion having a seat part and a backpart separated by an imperforate portion integral with the seat and backparts, the marginal portion of the seat and back parts having shortparallel slits therein, and springs Woven through the slits and urgingthe seat and back parts into coplanar relation to each other.

10. The cushion of claim 8, the cushion having separate seat and backparts and means adjustably connecting said parts comprising springsloosely woven through the adjacent marginal portions of the seat andback parts and means for securing the springs in adjusted positions insaid portions.

11. In a ventilating cushion having rows of aligned openingstherethrough and laterally extending supporting members bridging theopenings, a member of anti-friction material woven through each of anumber of selected rows of openings, the member having longitudinallyspaced apart portions thereof exposed at a surface of the cushion forcontact with a supporting surface thereby to resist slippage of thecushion on said supporting surface.

12. The cushion of claim 11, the member being a strip of fiat elastomermaterial.

13. In a ventilating cushion, a substantially imperforate marginalportion, stiffening means increasing the overall thickness of theperiphery of said portion, rows of transversely and longitudinallyspaced apart supporting elements projecting laterally from the cushionand integral therewith, there being openings in the cushion at each ofsaid elements, and elongate anti-friction members woven throughrespective selected rows of said openings.

14. The cushion of claim 13, the anti-friction members being flat rubberstrips.

15. A fabricated plastic member comprising a sheet of substantiallyuniform initial thickness having a first set of parallel longitudinallyextending continuous rows of strips of substantially uniform width,

a second set of parallel transversely extending rows of strips ofsubstantially uniform width intersecting the first set,

said sets of strips constituting a planar net-like stiffening web of theinitial uniform thickness of the sheet,

there being openings arranged in rows through the sheet between the rowsof both sets of strips,

the openings between adjacent rows of strips and in each row of openingsbeing spaced apart, and

a laterally outstanding arch-like element integral with the sheetmaterial of the strips at each end of each opening and bridging saidopening and having a top of slightly less length than and ofsubstantially the same width as that of said opening and in lateralspaced relation thereto, and

outwardly converging sides on the element integrally joining the top tothe adjacent strips of the second set.

16. The plastic member of claim 15, the strips of the second set beingof substantially undulating form.

17. The plastic member of claim 15, the sides of each element being oflesser thickness than that of the web.

18. The plastic member of claim 15, the elements at alternate openingsoutstanding laterally in one direction from the web and the elements atthe remaining openings outstanding laterally in the opposite directionfrom the web.

19. The plastic member of claim 14, the top of the element being flat,the sides of each element being of lesser thickness than that of theweb, the elements being sufficiently rigid and spaced closely enough tosupport a load.

References Cited in the file of this patent UNITED STATES PATENTS198,421 Smith Dec. 18, 1877 1,067,521 Jones July 15, 1913 1,490,554Bashkow et a1 Apr. 15, 1924 1,577,331 Lopez Mar. 16, 1926 2,454,912Cunningham Nov. 30, 1948 2,734,556 Hebrank Feb. 14, 1956 2,931,427Goldstein Apr. 5, 1960 2,948,333 Goldstein Aug. 9, 1960 2,948,334Goldstein Aug. 9, 1960 3,006,688 Ouellette Oct. 31, 1961

1. IN A FABRICATED EXPANDED PLASTIC MEMBER OF GREATER OVERALL HEIGHTTHAN THE THICKNESS OF THE MATERIAL THEREOF, A FORAMINOUS GENERALLYPLANAR ONE PIECE PORTION HAVING INTEGRAL SETS OF INTERSECTING STIFFENINGSTRIPS SURROUNDING AND DEFINING ROWS OF LONGITUDINALLY AND TRANSVERSELYSPACED APART OPENINGS IN SAID PORTION, AND OUTSTANDING GENERALLYARCH-SHAPED ELEMENTS INTEGRAL WITH SAID PORTION AND EACH BRIDGING ONE OFTHE OPENINGS AND HAVING A TOP OF SUBSTANTIAL AREA, THE ELEMENTS BEINGSUFFICIENTLY RIGID AND CLOSELY SPACED ENOUGH TO SUPPORT A LOAD, THEREBEING SPACES IN THE ELEMENTS COMMUNICATING WITH THE OPENINGS AND OFSUFFICIENT VOLUME FOR THE CIRCULATION OF AIR THROUGH THE MEMBER.